Filtration monitoring system

ABSTRACT

The present disclosure is a filtration monitoring system. Filtration monitoring system may include a sensor configured to measure a characteristic of usage of a monitored filter. The sensor may be communicatively coupled to a controller which is configured to transfer measured data to a server of the filter monitoring system. Server may be configured to store historical data regarding representative filter usage and may determine a predicted expiration time for a monitored filter which may be adjusted based upon the measured data from the sensor.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit under 35 U.S.C. § 120 of U.S.patent application Ser. No. 14/079,428 filed Nov. 13, 2013, pending.U.S. patent application Ser. No. 14/079,428 filed Nov. 13, 2013 claimsthe benefit under 35 U.S.C. § 119 of U.S. Provisional Application No.61/725,556, filed on Nov. 13, 2012.

The U.S. patent application Ser. No. 14/079,428 filed Nov. 13, 2013 andU.S. Provisional Patent Application No. 61/725,556 are herebyincorporated by reference in their entireties.

TECHNICAL FIELD

The present disclosure generally relates to the field of monitoringsystems, and more particularly to a filtration monitoring system.

BACKGROUND

Various types of products, including HVAC systems, air handlingequipment, and finishing spray booths employ various types of filters toremove impurities from the airflow. These respective systems may operatein an optimal fashion when the filters are regularly replaced. However,it is expensive to replace filters, and replacing filters prior to theirexpiration can exacerbate these costs. Furthermore, it may requirealmost-constant supervision to identify the exact moment the filtersreach an end of their useful life.

Conventional filters typically include a guide for replacement of thefilter based upon a suggested time or use interval, such as every threemonths, or a given value, such as static pressure levels. However,filters operate in many different environments and expiration of filtersmay fluctuate due to varying operating conditions.

SUMMARY

Accordingly, the present disclosure is directed to a filtrationmonitoring system. Filtration monitoring system may include a sensorconfigured to measure at least one characteristic of usage of amonitored filter. The sensor may be communicatively coupled to acontroller which is configured to transfer measured data to a server ofthe filter monitoring system. Server may be configured to storehistorical data regarding filter usage and may determine a predictedexpiration time for the monitored filter which may be adjusted basedupon the measured data from the sensor.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not necessarily restrictive of the present disclosure. Theaccompanying drawings, which are incorporated in and constitute a partof the specification, illustrate subject matter of the disclosure.Together, the descriptions and the drawings serve to explain theprinciples of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The numerous advantages of the present disclosure may be betterunderstood by those skilled in the art by reference to the accompanyingfigures in which:

FIG. 1 is a block diagram of a filtration monitoring system inaccordance with an embodiment of the present disclosure;

FIG. 2 illustrates a filtration monitoring system in accordance with anembodiment of the present disclosure;

FIG. 3 depicts a device of the filtration monitoring system inaccordance with an embodiment of the present disclosure;

FIG. 4 depicts an exemplary graph of measured data regarding acharacteristic of operation of a filter in accordance with an embodimentof the present disclosure;

FIG. 5 depicts an exemplary user interface depicting status of aplurality of filters in accordance with an embodiment of the presentdisclosure;

FIG. 6 depicts an exemplary service technician route for use in thescheduling of filter replacement in accordance with an exemplaryembodiment of the present disclosure;

FIG. 7 depicts an exemplary diagram of a plurality of filters inaccordance with an embodiment of the present disclosure; and

FIG. 8A and 8B depict an exemplary process flows for operation of thefiltration monitoring system in accordance with an embodiment of thepresent disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to the subject matter disclosed,which is illustrated in the accompanying drawings.

Before any embodiments of the disclosure are explained in detail, it isto be understood that the embodiments may not be limited in applicationaccording to the details of the structure or the function as set forthin the following descriptions or illustrated in the figures. Differentembodiments may be capable of being practiced or carried out in variousways. Also, it is to be understood that the phraseology and terminologyused herein is for the purpose of description and should not be regardedas limiting. The use of terms such as “including,” “comprising,” or“having” and variations thereof herein are generally meant to encompassthe item listed thereafter and equivalents thereof as well as additionalitems. Further, unless otherwise noted, technical terms may be usedaccording to conventional usage. It is further contemplated that likereference numbers may describe similar components and the equivalentsthereof.

Referring to FIG. 1, a block diagram of a filtration monitoring system100 in accordance with an embodiment of the present disclosure is shown.Filtration monitoring system 100 may determine a predicted expirationtime of a monitored filter to determine a time for replacement of themonitored filter. Filtration monitoring system 100 may include a sensor110 configured to measure at least one characteristic of usage of amonitored filter. It is contemplated that a monitored filter may be anytype or kind of filter in which a sensor 110 may be measuring acharacteristic of usage of the filter. Sensor 110 may be communicativelycoupled to a controller 120. Controller 120 may be configured totransfer measured data received from sensor 110 to a server 130 of thefilter monitoring system 100. Server 130 may be configured to storehistorical data regarding filter usage and may determine a predictedexpiration time for the monitored filter. Server 130 may further refinethe predicted expiration time of the monitored filter based upon receiptof measured data from the sensor 110. Filtration monitoring system 100may determine a predicted expiration time of a filter in residential,commercial and industrial HVAC systems, air handling equipment, spraybooths, water filters and the like.

It is contemplated that the predicted expiration time may account forpredicted non-use of the filter. Non-use of a filter may be determinedby server 130 by a zero reading measurement of sensor 110. For example,if a system that includes a monitored filter is not operating and sensor100 takes a measurement, a zero reading may be received. The zeroreading may alert the server 130 that the monitored filter is not inuse. A monitored filter may be utilized on weekdays and not used onweekends. If it is Friday morning and there is an estimated 12 hours ofoperating use remaining, the predicted expiration time may be Mondaymorning at 11:00 AM based upon nine hours of use on Friday and threehours of use on Monday, thus accounting for non-use in the evenings andon weekends. It is contemplated that server 130 may be programmed formonitoring of a particular monitored filter by allowing a user to entertimes of expected use and expected non-use which can be randomlyverified with measured data from sensor 110.

Server 130 may analyze historical usage data for a similar type offilter and may determine a predicted expiration time of a monitoredfilter. The predicted expiration time may be adjusted based uponmeasured data from the sensor 110. For example, if the measured datafrom sensor 110 indicates more wear than expected based upon thehistorical usage data, then the predicted expiration time may bereduced. Unlike other conventional monitoring systems, such as homesecurity systems, which only react to signals received from sensors, thefiltration monitoring system uses the measured data from sensor 110 toadjust the predicted expiration time accordingly. Conventionalmonitoring systems may rely upon a timer which only measures elapsedtime of usage. Filtration monitoring system 100 may account forvariables in the environment and fluctuations in the operatingconditions of the equipment employing the filter, such as spray volume,spray application transfer efficiencies, air pressure, motor efficiencychanges and the like.

Server 130 may be configured to direct the controller 120 and sensor 110to power on and take a measurement. It is contemplated that not manymeasurements may be necessary initially after a filter change, but canbe executed to determine if the equipment is in use or not in use. Byforegoing many measurements initially, battery power usage may bereduced. Server 130 may increase a frequency of measurements by sensor110 based on results of the measurements, particularly when thepredicted expiration time for the filter may be closer.

Server 130 may be configured to generate a user interface viewable by auser and may be configured for multi-media notification capability.Web-based user interface, shown in an exemplary embodiment in FIG. 5,may provide advanced notification regarding the predicted expirationtime for a monitored filter. Filtration monitoring system may include acommunication apparatus 140. Communication apparatus 140 may becommunicatively coupled with server 130. Communication apparatus 140 mayinclude a computer, tablet, mobile device, cellular phone, smartphoneand the like. Communication apparatus 140 may be associated with aninternal or external maintenance person who may be responsible forreplacing a monitored filter when it has expired. It is contemplatedcommunication apparatus 140 may include a location awareness componentto determine a geographical location of the communication apparatus 140.For example, communication apparatus 140 may include a globalpositioning system (GPS) receiver or other location awareness component.Server 130 may alert a designated person(s) via electronic mail, text,and voice phone calls via communication apparatus 140 regarding thepredicted expiration time for a monitored filter. Additionally, server130 may be configured for dispatch of service personnel or techniciansvia an alert sent to communication apparatus 140 at the predictedexpiration time of the monitored filter. Advantageously, filter life maybe maximized, labor efficiency may be increased, filter-relatedoperating costs may be decreased and filter holding costs and inventorycosts may be decreased.

Filtration monitoring system 100 may provide information to a userregarding the predicted expiration time for a monitored filter to adjusta change-out schedule to better accommodate their productionrequirements. For example, the predicted expiration time for a filtermay be at 6:00 pm, but the maintenance person responsible for changingfilters leaves at 5:00 pm. Through access to this predicted expirationtime information for a monitored filter and access to the current timeinformation and a work schedule of employees, server 130 may beconfigured to determine an appropriate time for replacement of themonitored filter. Server 130 may schedule the maintenance person toreplace the filter before leaving for the day or assigning replacementof the filter to another person.

Referring once again to FIG. 1, filtration monitoring system 100 mayinclude a sensor 110, a controller 120, a server 130 and a communicationapparatus 140. In one embodiment, sensor 110 may be a pressure sensor.Pressure sensor may be a differential pressure sensor. Differentialpressure sensor may measure a difference between two pressures, oneconnected to each side of the sensor. Differential pressure sensor maymeasure the pressure drop across a monitored filter. It is contemplatedthat as the pressure drop becomes larger across a filter, the filtercontains more impurities and thus is closer to expiration. It iscontemplated that sensor 110 may include other types of sensors withoutdeparting from the scope and intent of the present disclosure. Forexample, sensor 110 may include a flow sensor, an air flow sensor, airvelocity sensor, air mass sensor, temperature sensor, humidity sensorand the like.

Controller 120 may be configured to transfer measured data received fromsensor 110 to a server 130 of the filter monitoring system 100.Controller 120 may be coupled to server 130 via a wireless or hardwireconnection. Controller 120 may be configured for wireless transmissionof measured data received from sensor 110 and transfer the measured datato server 130. In one embodiment, controller 120 may include a wirelesstransceiver configured to receive measured data from sensor 110 andtransfer the measured data to server 130. While the sensor 110 andcontroller 120 may be identified separately, it is contemplated thatsensor 110 and controller 120 may be configured in a single component orset of components configured to measure a characteristic of use of themonitored filter and transfer the measured data to server 130.

In one embodiment, controller 120 may transmit data in accordance withIEEE 802.11 standard, generally referred as a WIFI transceiver.Controller 120 may be configured for transmission via RF, ZigBee (IEEE802.15.4), wired Ethernet (IEEE 802.3xx), wired Serial (RS-232/RS-485),cellular, infrared, BLUETOOTH, and the like without departing from thescope and intent of the present disclosure. It is further contemplatedthat sensor 110 and controller 120 may be coupled to a WIFI access pointwhereby server 130 may be communicatively coupled to the controller 120via the WIFI access point.

Server 130 may refer to a computing appliance and may include a databasefor storage of data. Server 130 may include a network interfaceconfigured to allow accessibility to a worldwide network, such as theworld wide web, and generally referred as the Internet. Server 130 mayinclude one or more processors configured to execute a program ofinstructions stored on computer readable media of a server 130 toreceive data from controller 120 and may issue commands to controller120 to direct sensor 110 to power on and take a measurement.

Referring to FIG. 2, a filtration monitoring system 200 in accordancewith an embodiment of the present disclosure is shown. Filtrationmonitoring system 200 may include one or more devices 210A, 210B tomeasure a characteristic of a monitored filter and transfer the measureddata to server 130. As shown in FIG. 2, it is contemplated thatfiltration monitoring system 200 may be operable to determine apredicted expiration time of a monitored filter in a paint spray booth.In such a fashion, devices 210A, 210B may be coupled to the input airflow and output air flow and configured to measure the differentialpressure drop across one or more filters of the spray booth. Inconventional spray booths, a pressure differential may be measuredacross a plurality of filters. In an embodiment of the disclosure, apressure differential may be measured across each filter of a spraybooth. However, it is contemplated that filtration monitoring system 200may determine a predicted expiration time of a filter in a HVAC system,water filters, and the like without departing from the scope and intentof the present disclosure.

Devices 210A, 210B may be employed to measure a characteristic of usageof a monitored filter. It is contemplated that multiple devices 210A,210B may be employed to test multiple filters, and multiple devices210A, 210B may also measure a characteristic of usage of a singlefilter. FIG. 3 depicts a device 210, which is representative of device210A, 210B of FIG. 2. Device 210 may include a sensor 110 and controller120 as described in FIG. 1 and may encapsulate the components of sensor110 and controller 120. Device 210 may include an antenna 214 forwireless transmission. It is contemplated that device 210 may include apower source, connected internally or externally to housing of device210, such as a battery or rechargeable battery. Also, device 210 mayinclude a connection to an electrical AC supply.

Device 210 may include user inputs (not shown). User inputs may be in aform of switches, buttons and the like. One user input may be a newfilter input. Each time a filter is changed, the new filter input may beengaged by a user to alert device 210 of a presence of a new filter. Itis contemplated that server 130 may be configured to determine a filterchange based upon the change of a characteristic associated with use ofthe filter. For example, a large differential pressure measurement of aparticular filter followed by a low differential pressure measurement ofthe same filter may alert server 130 to a filter change and server 130may update its information regarding that particular filter accordingly.Additionally, device 210 may include an unscheduled reading input. Anunscheduled reading input may be engaged by a user to force device 210to take a measurement of a filter.

While filtration monitoring system 100, 200 may be employed to determinea predicted expiration time of an air filter, filtration monitoringsystem 100, 200 may be employed to determine expiration of an aquariumfilter. A liquid sensor configured to measure a level or volume ofliquid, such as water, may compare a liquid level behind the aquariumfilter as compared to a front of the filter. When the level of waterreaches a threshold level, it may be an appropriate time to change thefilter. It is contemplated that in an aquarium filter, the water levelbehind the aquarium filter increases due to restrictions fromcontaminates in the filter. Contaminates may restrict water flow throughthe filter, which in turn, may increase the level of water behind theaquarium filter. The sensor may operate in a similar fashion as anautomobile gas tank sensor. As the liquid level may change, ameasurement may be taken. A predicted expiration time could bedetermined when the aquarium filter should be changed.

Referring to FIG. 4, an exemplary graph of measured data regarding acharacteristic of operation of a filter in accordance with an embodimentof the present disclosure. Graph 400 may be representative of thedifferential pressure measurements for a particular filter after afilter change, labeled in the graph as FC. It is contemplated that graph400 and its incline in measured differential pressure levels may be anaverage type of use, however, actual results will vary and thus themeasured data received from a sensor will affect the predictedexpiration time of the filter. Additionally, a sensor caution thresholdmay be set to alert when a filter should be considered for replacementand a sensor warning threshold may be set to alert when a filter needsreplacement.

It is contemplated that server 130 may maintain historical dataregarding prior filter usage, like that displayed for a particularfilter in FIG. 4. A representative filter may be employed to determine apredicted expiration time of a filter, currently in use. Therepresentative filter may include a similar characteristic as amonitored filter in use. This similar characteristic may include afilter type, filter size, filter manufacturer, filter environment, timeof year and the like. This data may be compiled to determine a predictedexpiration time of a monitored filter with at least one similarcharacteristic based upon the prior historical data.

Referring to FIG. 5, an exemplary user interface 500 depicting status ofa plurality of filters in accordance with an embodiment of the presentdisclosure is shown. User interface 500 may be a website accessible by auser to view status of the filters being maintained by a particularuser. It is contemplated that user interface 500 may include a nextscheduled reading of each monitored filter and a predicted expirationtime for each filter being maintained by each particular user. Also,logos and styling of the user interface 500 may be customized to aparticular user whereby the particular user would only be able to viewinformation concerning its filters. It is further contemplated that userinterface 500 may include a “buy now” feature to purchase a replacementfilter. Replacement filter may be delivered at the time of the predictedexpiration time of a filter.

Referring to FIG. 6, an exemplary service technician route 600 for usein the scheduling of filter replacement in accordance with an exemplaryembodiment of the present disclosure is shown. It is contemplated thatserver 130 of filtration monitoring system 100, 200 may be operable witha plurality of users of filters. As each user may include one or morefilters, it is contemplated that filters may need replacement at avariety of locations. Filtration monitoring system 100, 200 may beoperable with filter replacement service personnel whereby a deliveryschedule is prepared based upon the predicted expiration times of thefilters of the users and the geographical location of the filters. Forexample, it is contemplated that replacement of the filter may bedesired at a time close to the predicted expiration time.

In an embodiment of the present disclosure, server 130 is configured toaccount for a variety of factors in the determination of a service routetechnician. The variety of factors may include the determination of anefficient route based upon the geographical locations of the servicetechnician and locations requiring a filter replacement, day, time ofday, traffic data, weather data, operating times for the businesses inwhich the filter needs replacement and the like.

Referring once again to FIG. 6, if the predicted expiration timecorresponded with a filter expiring first at location 612, then a filterexpiring at location 616, then a filter expiring at location 614. If theschedule was solely based upon the predicted expiration time, server 130may produce a service technician route of location 612, and thenlocation 616 followed by location 614. Server 130, in accordance with anembodiment of the disclosure, may be configured to determine a mostefficient service technician route. Server 130 may analyze the predictedexpiration time of filters and locations requiring a filter replacement,day, time of day, traffic data, weather data, operating times for thebusinesses in which the filter needs replacement to determine the mostefficient service technician route. As such, in this example, the mostefficient service technician route may be determined to replace thefilter at location 616, then the filter at location 612, then the filterat location 614.

It is contemplated that server 130 may continuously update the servicetechnician route in real-time. As such, a service technician may accesshis/her work schedule via a mobile device configured to access server130 after each filter replacement in order to determine the nextlocation for a filter replacement.

Referring to FIG. 7, an exemplary diagram 700 of a plurality of filtersin accordance with an embodiment of the present disclosure. Diagram 700may be representative of a building location with a plurality of filterslocated on multiple floors. A replacement schedule for filters locatedin various locations of a building may be determined based upon thepredicted expiration time for each filter and the location of the filterin the building. For example, the replacement schedule may be based uponthe predicted expiration time of each filter and the location of eachfilter in the building to determine an efficient replacement schedule.For example, if the predicted expiration time corresponded with a filterexpiring first at location 712, then a filter expiring at location 715,then a filter expiring at location 714. Due to the proximity oflocations 712, 714, the most efficient replacement schedule may bedetermined to replace the filter at location 715, then the filter atlocation 712, then the filter at location 714.

Referring to FIG. 8A and FIG. 8B, exemplary process flows for operationof the filtration monitoring system 100, 200 are shown in accordancewith an embodiment of the present disclosure is shown. Filtrationmonitoring system may be employed to operate with a coordinated centralmaintenance facility with one or more service technicians employed todeliver and install filters at or near the predicted expiration time offilters.

In the present disclosure, the methods disclosed may be implemented assets of instructions or software readable by a device. Further, it isunderstood that the specific order or hierarchy of steps in the methodsdisclosed are examples of exemplary approaches. Based upon designpreferences, it is understood that the specific order or hierarchy ofsteps in the method can be rearranged while remaining within thedisclosed subject matter. The accompanying method claims presentelements of the various steps in a sample order, and are not necessarilymeant to be limited to the specific order or hierarchy presented.

It is believed that the present disclosure and many of its attendantadvantages will be understood by the foregoing description, and it willbe apparent that various changes may be made in the form, constructionand arrangement of the components without departing from the disclosedsubject matter or without sacrificing all of its material advantages.The form described is merely explanatory, and it is the intention of thefollowing claims to encompass and include such claims.

What is claimed is:
 1. A filtration monitoring system, comprising: asensor configured to measure a characteristic of usage of a monitoredfilter; a controller communicatively coupled to the sensor, saidcontroller configured to receive measured data of said characteristic ofusage of said monitored filter from said sensor, the controllerincluding a wireless transceiver; a server communicatively coupled tosaid controller, wherein said server is configured to retrievehistorical data regarding usage of a representative filter to determinea predicted expiration time of said monitored filter, said serverconfigured to adjust said predicted expiration time of said monitoredfilter based upon the measured data received from said controller,wherein said predicted expiration time accounts for estimated periods ofuse of said monitored filter and accounts for estimated periods ofnon-use of said monitored filter.
 2. The filtration monitoring system ofclaim 1, wherein said sensor includes a differential pressure sensor. 3.The filtration monitoring system of claim 2, wherein said differentialpressure sensor is configured to measure a differential pressure acrosssaid monitored filter.
 4. The filtration monitoring system of claim 1,wherein said wireless transceiver is configured to transmit dataaccording to IEEE 802.11standard.
 5. The filtration monitoring system ofclaim 1, wherein said representative filter shares at least onecharacteristic in common with said monitored filter.
 6. The filtrationmonitoring system of claim 5, wherein said at least one characteristicin common with said monitored filter includes one of filter type, filtersize, filter manufacturer, or filter environment.
 7. The filtrationmonitoring system of claim 1, wherein said server is configured to senda notification to a user regarding the predicted expiration time of saidmonitored filter.
 8. The filtration monitoring system of claim 1,wherein said server is configured to schedule a replacement of saidmonitored filter at a time approximately near the predicted expirationtime of said monitored filter.
 9. The filtration monitoring system ofclaim 1, wherein said server is configured to generate a graphical userinterface accessible by a user via a worldwide network, said graphicaluser interface including information regarding the predicted expirationtime of said monitored filter.
 10. The filtration monitoring system ofclaim 1, wherein said monitored filter is an air filter.
 11. Afiltration monitoring system, comprising: a differential pressure sensorconfigured to measure a differential pressure across a monitored airfilter; a wireless transceiver communicatively coupled to thedifferential pressure sensor, said wireless transceiver configured toreceive measured differential pressure data across said monitored airfilter from said differential pressure sensor; a server communicativelycoupled to said wireless transceiver, wherein said server is configuredto retrieve historical data regarding usage of a representative filterto determine a predicted expiration time of said monitored air filter,said server configured to adjust said predicted expiration time of saidmonitored air filter based upon the measured differential pressure datareceived from said wireless transceiver, said server configured toretrieve the historical data regarding usage of the representativefilter in combination with the measured differential pressure data todetermine the predicted expiration time of the monitored air filter,said predicted expiration time accounts for estimated periods of use ofsaid monitored air filter and accounts for estimated periods of non-useof said monitored air filter.
 12. The filtration monitoring system ofclaim 11, wherein said representative filter is a similar filter typeand a similar filter size.
 13. The filtration monitoring system of claim11, wherein said server is configured to send a notification to a userregarding the predicted expiration time of said monitored air filter.14. The filtration monitoring system of claim 11, wherein said server isconfigured to schedule a replacement of said monitored air filter at atime approximately near the predicted expiration of said monitored airfilter.
 15. The filtration monitoring system of claim 11, wherein saidserver is configured to generate a graphical user interface accessibleby a user via a worldwide network, said graphical user interfaceincluding information regarding the predicted expiration time of saidmonitored air filter.
 16. A filtration monitoring system, comprising: asensor configured to measure a characteristic of usage of a monitoredfilter; a transceiver communicatively coupled to the sensor, saidtransceiver configured to receive the characteristic of usage of themonitored filter from the sensor; a server communicatively coupled tosaid transceiver, wherein said server is configured to retrievehistorical data regarding usage of a representative filter to determinea predicted expiration time of said monitored filter, said serverconfigured to adjust said predicted expiration time of said monitoredfilter based upon measured data received from said transceiver, saidserver configured to retrieve the historical data regarding usage of therepresentative filter in combination with the measured data to determinethe predicted expiration time of the monitored filter, said predictedexpiration time accounts for estimated periods of use of said monitoredfilter and accounts for estimated periods of non-use of said monitoredfilter.
 17. The filtration monitoring system of claim 16, wherein saidserver is configured to send a notification to a user regarding thepredicted expiration time of said monitored filter.
 18. The filtrationmonitoring system of claim 16, wherein said server is configured toschedule a replacement of said monitored filter at a time approximatelynear the predicted expiration of said monitored filter.
 19. Thefiltration monitoring system of claim 16, wherein said server isconfigured to generate a graphical user interface accessible by a uservia a worldwide network, said graphical user interface includinginformation regarding the predicted expiration time of said monitoredfilter.